Surgical instrument with separable shaft assembly and body

ABSTRACT

A surgical instrument includes a body, a shaft assembly, and an end effector. The shaft assembly extends distally from the body. The end effector is located at a distal end portion of the shaft assembly. The end effector includes an active feature configured to operate on tissue. The body includes a drive feature operable to drive the active feature of the end effector. The body is removably coupled with the shaft assembly in a connected state and separated from the shaft assembly in a disconnected state. The body includes a drive feature configured to drive operation of the active feature of the effector. The drive feature includes at least one of an ultrasonic drive feature or a mechanical drive feature. A proximal end portion of the shaft assembly is configured to be removed from the body to separate the at least one activation feature from the drive feature.

PRIORITY

This application is a continuation of U.S. application Ser. No.15/680,484, filed Aug. 18, 2017 and published as U.S. Pat. Pub. No.2018/0028182 on Feb. 1, 2018, issued as U.S. Pat. No. 10,675,027 on Jun.9, 2020, entitled “Surgical Instrument with Selectable Integral orExternal Power Source,” which is a divisional application of U.S.Nonprovisional patent application Ser. No. 13/804,417, filed Mar. 14,2013 and published as U.S. Pat. Pub. No. 2014/0207124 on Jul. 24, 2014,now abandoned, entitled “Surgical Instrument with Selectable Integral orExternal Power Source,” which claims priority to U.S. Provisional Pat.App. No. 61/755,607, entitled “Surgical Instrument with SelectableIntegral or External Power Source,” filed Jan. 23, 2013, the disclosuresdisclosure of which are incorporated by reference herein.

BACKGROUND

A variety of surgical instruments rely at least in part on electricalpower to operate. Examples of such instruments include some versions ofsurgical stapling and cutting instruments, ultrasonic surgicalinstruments, and electrosurgical instruments. An example of anelectrically powered surgical stapling and cutting instrument is theECHELON FLEX™ Powered ENDOPATH® Stapler by Ethicon Endo-Surgery, Inc. ofCincinnati, Ohio. Further examples of such devices and related conceptsare disclosed in U.S. Pat. No. 7,416,101 entitled “Motor-Driven SurgicalCutting and Fastening Instrument with Loading Force Feedback,” issuedAug. 26, 2008, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2009/0209990 entitled “Motorized Surgical Cuttingand Fastening Instrument Having Handle Based Power Source,” publishedAug. 20, 2009 and issued as U.S. Pat. No. 8,657,174 on Feb. 25, 2014,the disclosure of which is incorporated by reference herein; U.S. Pub.No. 2012/0239012, entitled “Motor-Driven Surgical Cutting Instrumentwith Electric Actuator Directional Control Assembly,” published Sep. 20,2012, and issued as U.S. Pat. No. 8,453,914 on Jun. 4, 2013, thedisclosure of which is incorporated by reference herein; and U.S. patentapplication Ser. No. 13/716,308, entitled “Circular Stapler withSelectable Motorized and Manual Control,” filed Dec. 17, 2012 and issuedas U.S. Pat. No. 9,445,816 on Sep. 20, 2016, the disclosure of which isincorporated by reference herein.

Examples of ultrasonic surgical instruments include the HARMONIC ACE®Ultrasonic Shears, the HARMONIC FOCUS® Ultrasonic Shears, and theHARMONIC SYNERGY® Ultrasonic Blades, all by Ethicon Endo-Surgery, Inc.of Cincinnati, Ohio. Further examples of such devices and relatedconcepts are disclosed in U.S. Pat. No. 5,322,055 entitled “ClampCoagulator/Cutting System for Ultrasonic Surgical Instruments,” issuedJun. 21, 1994, the disclosure of which is incorporated by referenceherein; U.S. Pat. No. 5,873,873 entitled “Ultrasonic Clamp CoagulatorApparatus Having Improved Clamp Mechanism,” issued Feb. 23, 1999, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.5,980,510, entitled “Ultrasonic Clamp Coagulator Apparatus HavingImproved Clamp Arm Pivot Mount,” filed Oct. 10, 1997, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,325,811entitled “Blades with Functional Balance Asymmetries for use withUltrasonic Surgical Instruments,” issued Dec. 4, 2001, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,783,524,entitled “Robotic Surgical Tool with Ultrasound Cauterizing and CuttingInstrument,” issued Aug. 31, 2004; U.S. Pub. No. 2006/0079874 entitled“Tissue Pad for Use with an Ultrasonic Surgical Instrument,” publishedApr. 13, 2006 and now abandoned, the disclosure of which is incorporatedby reference herein; U.S. Pub. No. 2007/0191713 entitled “UltrasonicDevice for Cutting and Coagulating,” published Aug. 16, 2007 and nowabandoned, the disclosure of which is incorporated by reference herein;U.S. Pub. No. 2007/0282333 entitled “Ultrasonic Waveguide and Blade,”published Dec. 6, 2007 and now abandoned, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2008/0200940 entitled“Ultrasonic Device for Cutting and Coagulating,” published Aug. 21, 2008and now abandoned, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2010/0069940 entitled “Ultrasonic Device forFingertip Control,” published Mar. 18, 2010 and issued as U.S. Pat. No.9,023,071 on May 5, 2015, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2011/0015660, entitled “RotatingTransducer Mount for Ultrasonic Surgical Instruments,” published Jan.20, 2011, and issued as U.S. Pat. No. 8,461,744 on Jun. 11, 2013, thedisclosure of which is incorporated by reference herein; and.Additionally, some of the foregoing surgical tools may include acordless transducer such as that disclosed in U.S. Pub. No.2012/0112687, entitled “Recharge System for Medical Devices,” publishedMay 10, 2012 and issued as U.S. Pat. No. 9,381,058 on Jul. 5, 2016, thedisclosure of which is incorporated by reference herein; U.S. Pub. No.2012/0116265, entitled “Surgical Instrument with Charging Devices,”published May 10, 2012 and now abandoned, the disclosure of which isincorporated by reference herein; and/or U.S. Pat. App. No. 61/410,603,filed Nov. 5, 2010, entitled “Energy-Based Surgical Instruments,” thedisclosure of which is incorporated by reference herein.

A variety of electrosurgical instruments include a tissue cuttingelement and one or more elements that transmit RF energy to tissue(e.g., to coagulate or seal the tissue). An example of such a device isthe ENSEAL® Tissue Sealing Device by Ethicon Endo-Surgery, Inc., ofCincinnati, Ohio. Further examples of such devices and related conceptsare disclosed in U.S. Pat. No. 6,500,176 entitled “ElectrosurgicalSystems and Techniques for Sealing Tissue,” issued Dec. 31, 2002, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.7,112,201 entitled “Electrosurgical Instrument and Method of Use,”issued Sep. 26, 2006, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,125,409, entitled “ElectrosurgicalWorking End for Controlled Energy Delivery,” issued Oct. 24, 2006, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.7,169,146 entitled “Electrosurgical Probe and Method of Use,” issuedJan. 30, 2007, the disclosure of which is incorporated by referenceherein; U.S. Pat. No. 7,186,253, entitled “Electrosurgical Jaw Structurefor Controlled Energy Delivery,” issued Mar. 6, 2007, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,189,233,entitled “Electrosurgical Instrument,” issued Mar. 13, 2007, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.7,220,951, entitled “Surgical Sealing Surfaces and Methods of Use,”issued May 22, 2007, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,309,849, entitled “PolymerCompositions Exhibiting a PTC Property and Methods of Fabrication,”issued Dec. 18, 2007, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,311,709, entitled “ElectrosurgicalInstrument and Method of Use,” issued Dec. 25, 2007, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,354,440,entitled “Electrosurgical Instrument and Method of Use,” issued Apr. 8,2008, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 7,381,209, entitled “Electrosurgical Instrument,” issued Jun.3, 2008, the disclosure of which is incorporated by reference herein.

Additional examples of electrosurgical cutting instruments and relatedconcepts are disclosed in U.S. Pub. No. 2011/0087218, entitled “SurgicalInstrument Comprising First and Second Drive Systems Actuatable by aCommon Trigger Mechanism,” published Apr. 14, 2011 and issued as U.S.Pat. No. 8,939,974 on Jan. 27, 2015, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0116379, entitled“Motor Driven Electrosurgical Device with Mechanical and ElectricalFeedback,” published May 10, 2012 and issued as U.S. Pat. No. 9,161,803on Oct. 20, 2015, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2012/0078243, entitled “Control Features forArticulating Surgical Device,” published Mar. 29, 2012 and issued asU.S. Pat. No. 9,877,720 on Jan. 30, 3018, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0078247, entitled“Articulation Joint Features for Articulating Surgical Device,”published Mar. 29, 2012 and issued as U.S. Pat. No. 9,402,682 on Aug. 2,2016, the disclosure of which is incorporated by reference herein; U.S.patent application Ser. No. 13/622,729, entitled “Surgical Instrumentwith Multi-Phase Trigger Bias,” filed Sep. 19, 2012, and issued as U.S.Pat. No. 9,089,327 on Jul. 28, 2015, the disclosure of which isincorporated by reference herein; U.S. patent application Ser. No.13/622,735, entitled “Surgical Instrument with Contained Dual HelixActuator Assembly,” filed Sep. 19, 2012, and issued as U.S. Pat. No.9,545,253 on Jan. 17, 2017, the disclosure of which is incorporated byreference herein; and U.S. patent application Ser. No. 13/658,784,entitled “Litz Wire Battery Powered Device,” filed Oct. 23, 2012, andissued as U.S. Pat. No. 9,421,060 on Aug. 23, 2016, the disclosure ofwhich is incorporated by reference herein.

While several electrically powered surgical instruments have been madeand used, it is believed that no one prior to the inventor(s) has madeor used the invention described herein and in any claims appendedhereto.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a block schematic view of an exemplary surgicalinstrument with interchangeable power source options;

FIG. 2 depicts an electrical schematic view of exemplary circuitry thatmay be incorporated into the corded power source option of FIG. 1 ;

FIG. 3 depicts a perspective view of an exemplary surgical staplinginstrument with a battery inserted in the handpiece;

FIG. 4 depicts a perspective view of the stapling instrument of FIG. 3 ,with the battery removed from the handpiece;

FIG. 5 depicts a perspective view of the stapling instrument of FIG. 3 ,with a corded power adapter positioned for insertion in the handpiece;

FIG. 6 depicts a perspective view of an exemplary ultrasonic surgicalinstrument handpiece, with a battery positioned for insertion in thehandpiece via a sterile interface component;

FIG. 7 depicts a side cross-sectional view of the sterile interfacecomponent of FIG. 6 ;

FIG. 8 depicts a perspective view of the ultransonic surgical instrumentof FIG. 6 , with a corded power adapter positioned for insertion in thehandpiece via the sterile interface component;

FIG. 9 depicts a side view of another exemplary ultrasonic surgicalinstrument handpiece, including a removable grip portion;

FIG. 10 depicts a side view of yet another exemplary ultrasonic surgicalinstrument handpiece including a removable grip portion;

FIG. 11 depicts a block schematic view of an exemplary surgicalinstrument with an integral power source and a supplemental power cord;

FIG. 12 depicts a side view of an exemplary ultrasonic surgicalinstrument handpiece, including an integral power source and asupplemental power cord positioned for coupling with the handpiece;

FIG. 13 depicts a block schematic view of an exemplary alternative plugassembly;

FIG. 14 depicts a side elevational view of an exemplary handpiececonfigured to receive a modular shaft assembly;

FIG. 15 depicts a side elevational view of an exemplary shaft assemblyconfigured to couple with the handpiece of FIG. 14 ;

FIG. 16 depicts a side elevational view of another exemplary shaftassembly configured to couple with the handpiece of FIG. 14 ;

FIG. 17 depicts a side elevational view of another exemplary shaftassembly configured to couple with the handpiece of FIG. 14 ;

FIG. 18 depicts a side elevational view of another exemplary handpiececonfigured to receive a modular shaft assembly;

FIG. 19 depicts a perspective view of an exemplary shaft assemblyconfigured to couple with the handpiece of FIG. 18 ;

FIG. 20 depicts a perspective view of another exemplary shaft assemblyconfigured to couple with the handpiece of FIG. 18 ;

FIG. 21 depicts a side elevational view of another exemplary handpiececonfigured to receive a modular shaft assembly;

FIG. 22 depicts a side elevational view of an exemplary shaft assemblyconfigured to couple with the handpiece of FIG. 21 ;

FIG. 23 depicts a side elevational view of another exemplary shaftassembly configured to couple with the handpiece of FIG. 21 ; and

FIG. 24 depicts a side elevational view of another exemplary shaftassembly configured to couple with the handpiece of FIG. 21 .

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

It is further understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Thefollowing-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

I. Exemplary Surgical Instrument with Interchangeable Power SourceOptions

Those of ordinary skill in the art will recognize that battery powereddevices may present their own advantages and disadvantages; while cordeddevices may present a different set of advantages and disadvantages. Itmay therefore be desirable in some instances to provide a device that iscapable of providing the desired advantages of battery power or cordedpower, or perhaps avoiding disadvantages of battery power or cordedpower, based on the particular circumstances at hand. FIG. 1 illustratesan exemplary surgical instrument (10) that is capable of operating onbattery power or corded power, as selected by the operator. Surgicalinstrument (10) of this example includes a control module (12), an endeffector (14), a sensor (16), a user input (18), and a power socket(20). End effector (14), sensor (16), user input (18), and power socket(20) are all in communication with control module (12) via wires (22).Control module (12) is thus operable to receive inputs (e.g., power,data, etc.) from end effector (14), sensor (16), user input (18), and/orpower socket (20); and to drive end effector (14) based on one or morecontrol algorithms and based on input received from sensor (16) and/oruser input (18). Control module (12) may comprise a microprocessor, anapplication specific integrated circuit (ASIC), memory, a printedcircuit board (PCB), a storage device (such as a solid state drive orhard disk), firmware, software, and/or various other suitable componentsas will be apparent to those of ordinary skill in the art in view of theteachings herein. Wires (22) may comprise any suitable conventionalwiring, traces in rigid circuit boards or flexible circuits, and/or anyother suitable components that are operable to communicate electricalpower and/or data/signals.

End effector (14) may include a variety of features that are operable tomanipulate tissue. By way of example only, end effector (14) may includeone or more movable jaws that are operable to grasp tissue, a tissuecutting feature (e.g., translating knife blade), a set of staples andstaple drivers operable to sever tissue, an ultrasonic blade operable todenature proteins in tissue by applying ultrasonic energy to the tissue,one or more electrodes operable to provide RF energy (e.g., bipolar ormonopolar) to tissue, and/or any other suitable features as will beapparent to those of ordinary skill in the art in view of the teachingsherein. End effector (14) of this example comprises an active feature,such as an ultrasonic blade, a pair of clamping jaws, a sharp knife, astaple driving assembly, a monopolar RF electrode, a pair of bipolar RFelectrodes, a thermal heating element, and/or various other componentsthat may be driven by electrical power. In some instances, end effector(14) is removable from the rest of surgical instrument (10) forservicing, testing, replacement, or any other purpose as will beapparent to one of ordinary skill in the art in view of the teachingsherein. It should also be understood that surgical instrument (10) maybe configured to accept various kinds of end effectors (14) to performdifferent kinds of activities. For instance, surgical instrument (10)may accept a removable stapling end effector (14), which may be removedand replaced with an electrosurgical end effector (14), which may beremoved and replaced with an ultrasonic end effector (14), and so on.

Sensor (16) of the present example is operable to provide a variety ofinformation to control module (12) during a procedure. By way of exampleonly, such configurations may include sensing a temperature at endeffector (14) or determining the oscillation rate of end effector (14).Data from sensor (16) may be processed by control module (12) to effectthe delivery of power to end effector (14) (e.g., in a feedback loop,etc.). Various other configurations of sensor (16) may be provideddepending upon the purpose of surgical instrument (10) as will beapparent to those of ordinary skill in the art in view of the teachingsherein. Various suitable uses for sensor (16) and various forms thatsensor (16) may take will be apparent to those of ordinary skill in theart in view of the teachings herein. Of course, as with other componentsdescribed herein, surgical instrument (10) may have more than one sensor(16); or sensor (16) may simply be omitted if desired.

Trigger (18) may be configured to selectively provide power from theselected power source (40, 60) to end effector (14) (and/or to someother component of surgical instrument (10)) to activate surgicalinstrument (10) when performing a procedure. By way of example only,trigger (18) may comprise one or more pushbuttons, one or more pivotingtriggers, one or more sliders, one or more knobs, and/or variations andcombinations thereof. Other suitable forms that trigger (18) may takewill be apparent to those of ordinary skill in the art in view of theteachings herein.

Power socket (20) is operable to removably receive a power source (40,50) and thereby power control module (12) and end effector (14). Inparticular, power socket (20) is operable to removably receive either abattery (40) or a plug (50). Power socket (20) may include electricalcontacts, inductive coupling features, capacitive coupling features,and/or any other suitable type(s) of features that are operable tocommunicate power from power source (40, 50) to control module (12) whenpower source (40, 50) is fully coupled with power socket (20). Battery(40) may comprise a pack of one or more NiMH batteries, Li-ion batteries(e.g., prismatic cell type lithium ion batteries, etc.), Ni-Cadbatteries, or any other type of portable power source as may be apparentto one of ordinary skill in the art in light of the teachings herein.Battery (40) may be rechargeable or not, as desired. When coupled withpower socket (20), battery (40) is operable to provide enough power tocontrol module (12) and end effector (14) to perform at least part of asurgical procedure using an activated component of end effector (14).

Plug (50) of the present example is coupled with an integral cable (52),which is further removably coupled with a generator (60). Plug (50) andcable (52) may be provided as disposable components or as reusable,sterilizable components. Generator (60) may be coupled with aconventional AC wall outlet (not shown) and is operable to convert powerfrom a conventional AC wall outlet into power suited for use in surgicalinstrument (10). In some versions, generator (60) comprises a GilGenerator by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio. Generator(60) may be operable to vary its power output mode based on whethersurgical instrument (10) is an ultrasonic surgical instrument, anelectrosurgical instrument, etc. Variations in power output mode may bemanually selected by the operator; or may be automatically selected bygenerator (60) sensing the type of instrument that is coupled withgenerator (60). By way of example only, generator (60) may beconstructed in accordance with at least some of the teachings of U.S.Pub. No. 2011/0015631, entitled “Ultrasonic Surgical Instruments,”published Jan. 20, 2011 and issued as U.S. Pat. No. 8,663,220 on Mar. 4,2014, the disclosure of which is incorporated by reference herein; U.S.Pub. No. 2011/0087212, entitled “Surgical Generator for Ultrasonic andElectrosurgical Devices,” published Apr. 14, 2011 and issued as U.S.Pat. No. 8,986,302 on Mar. 24, 2015, the disclosure of which isincorporated by reference herein; and/or U.S. Pub. No. 2011/0087256,entitled “Surgical Generator for Ultrasonic and ElectrosurgicalDevices,” published Apr. 14, 2011 and issued as U.S. Pat. No. 9,060,775on Jun. 23, 2015, the disclosure of which is incorporated by referenceherein. In the present example, generator (60) is operable tocommunicate electrical power through cable (52) to plug (50), to therebypower surgical instrument (10).

It should also be understood that cable (52) and plug (50) may befurther operable to provide unidirectional or bidirectionalcommunication of data and/or commands, etc. between surgical instrument(10) and generator (60). By way of example only, data may becommunicated through cable (52) and plug (50) in accordance with atleast some of the teachings of U.S. Pub. No. 2012/0116367, entitled“Medical Device Usage Data Processing,” published May 10, 2012 andissued as U.S. Pat. No. 9,095,346 on Aug. 4, 2015, the disclosure ofwhich is incorporated by reference herein. In addition or on thealternative, such data may include software/firmware upgrades for one ormore components of instruments (10); data used to provide authenticationof instrument (10), plug (50), and/or generator (60); usage trackingdata; auto-configuration data to tailor performance of instrument (10)based on the particular operator using instrument (10); datarepresenting events stored on instrument (10); data captured in realtime during use of instrument (10) (e.g., temperature, tissue impedance,etc.); and/or various other kinds of data. In versions where operabilityof instrument (10) is tailored based on the particular operator usinginstrument, such tailoring may be provided in accordance with at leastsome of the teachings of U.S. patent application Ser. No. 13/426,760,entitled “Method and Apparatus for Programming Modular SurgicalInstrument,” filed Mar. 22, 2012, and issued as U.S. Pat. No. 9,364,249on Jun. 14, 2016, the disclosure of which is incorporated by referenceherein. It should also be understood that generator (60) may be capableof performing diagnostics on instrument (10) via cable (52) and plug(50).

In addition or in the alternative to being provided through cable (52)and plug (50), at least some of the above-described data communicationfunctionality may be provided wirelessly between instrument (10) andgenerator (60); and/or between instrument (10) and some other piece ofequipment. By way of example only, such wireless communication may beprovided using a Bluetooth protocol, a Zigbee protocol, some otherprotocol, or even some other modality (e.g., non-RF wirelesscommunication, etc.). Such wireless communication may be provided wheninstrument (10) is coupled with battery (40); and in some instances evenwhen instrument (10) is coupled with plug (50) and cable (52). While theabove-described example includes data communication between instrument(10) and generator (60), it should be understood that data may becommunicated between instrument (10) and some other piece of equipment,wirelessly or via wire, in addition to or in lieu of being communicatedbetween instrument (10) and generator (60). By way of example only, datamay be communicated from instrument (10) to a laparoscopic cameradisplay. Other types of equipment that instrument (10) may communicatewith will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

Generator (60) may also be capable of providing user feedback (e.g.,audible tones, lights, graphical/textual messages, etc.) that instrument(10) might otherwise be incapable of providing when instrument (10) isdriven by battery (40). Such user feedback at generator (60) may bedriven by data received through cable (52) and plug (50). For instance,the user feedback may indicate when end effector (14) is beingactivated, when a cycle has completed, when a timer has run, when thereis an alert condition, instructions for setup, troubleshooting, thelongitudinal position of a translating knife in end effector (14), thethickness of tissue clamped between jaws of end effector (14), etc. Someversions of instrument (10) may be configured to provide user feedbackthrough instrument itself (10). For instance, instrument (10) mayprovide user feedback in accordance with at least some of the teachingsof U.S. Pub. No. 2012/0116364, entitled “User Feedback through Handpieceof Surgical Instrument,” published May 10, 2012 and issued as U.S. Pat.No. 9,364,279 on Jun. 14, 2016, the disclosure of which is incorporatedby reference herein and/or U.S. Pub. No. 2012/0116267, entitled “UserFeedback trough End Effector of Surgical Instrument,” published May 10,2012 and issued as U.S. Pat. No. 9,526,921 on Dec. 27, 2016, thedisclosure of which is incorporated by reference herein. Even ininstances where instrument (10) is capable of providing user feedback onits own, such user feedback features of instrument (10) may be bypassedin favor of providing the user feedback through generator (60) wheninstrument (10) is coupled with generator (60) via cable (52) and plug(50). Alternatively, user feedback provided through generator (60) maysupplement user feedback provided through instrument (10).

In some versions, instrument (10) communicates data (e.g., tissueimpedance, other electrosurgical performance data, etc.) to generator(60) and/or to some other smart receiver; and then the generator (60)and/or other smart receiver communicates information back to instrument(10) to instruct instrument (10) to output certain user feedback. Thus,even in instances where instrument (10) itself provides user feedback,such user feedback may be driven at least in part by instructions fromgenerator (60), with such instructions being based at least in part bydata communicated from instrument (10) to generator (60). The data frominstrument (10) to generator (60) and/or the user feedback commands fromgenerator (60) to instrument (10) may be communicated via cable (52) andplug (50) and/or otherwise.

It should also be understood that instrument (10) may communicate datawirelessly to generator (60) to provide the user feedback throughgenerator (60). Again, such wireless communication may be provided usinga Bluetooth protocol, a Zigbee protocol, some other protocol, or evensome other modality (e.g., non-RF wireless communication, etc.). Suchwireless communication may also be provided when instrument (10) iscoupled with battery (40); and in some instances even when instrument(10) is coupled with plug (50) and cable (52).

While the above-described example includes data communication betweeninstrument (10) and generator (60) for providing user feedback, itshould be understood that data may be communicated between instrument(10) and some other piece of equipment, wirelessly or via wire, inaddition to or in lieu of being communicated between instrument (10) andgenerator (60), to provide user feedback. By way of example only, datamay be communicated from instrument (10) to a laparoscopic cameradisplay, wirelessly or via wire, such that the laparoscopic cameradisplay may provide audible and/or visual feedback to the user based ondata from instrument (10). As yet another merely illustrative variation,data from instrument (10) may be relayed from generator (60) to anotherpiece of equipment (e.g., a laparoscopic camera display), with anysuitable combination of wires or wireless technology to providecommunication between links in the chain of communication. As stillanother merely illustrative example, data may be relayed to a server inaccordance with at least some of the teachings of U.S. patentapplication Ser. No. 13/426,792, entitled “Surgical Instrument UsageData Management,” filed Mar. 22, 2012, and published Sep. 26, 2013 asU.S. Pub. No. 2013/0253480 and now abandoned, the disclosure of which isincorporated by reference herein.

Those of ordinary skill in the art will recognize that theabove-described wireless communication examples may be carried out innumerous ways. By way of example only, wireless communication may becarried out in accordance with at least some of the teachings of U.S.Pub. No. 2012/0116381, entitled “Surgical Instrument with ChargingStation and Wireless Communication,” published May 10, 2012 and nowabandoned, the disclosure of which is incorporated by reference herein;and/or U.S. Pub. No. 2012/0116365, entitled “Surgical Instrument SafetyGlasses,” published May 10, 2012 and issued as U.S. Pat. No. 9,011,427on Apr. 21, 2015, the disclosure of which is incorporated by referenceherein. Other suitable ways in which the above-described wirelesscommunication examples may be carried out will be apparent to those ofordinary skill in the art in view of the teachings herein.

While cable (52) and plug (50) are integral in the present example,these components may be separable in some other versions. For instance,in some versions cable (52) may comprise a conventional cable that istypically used with generator (60); and plug (50) may be provided as anadapter that cable (52) plugs into. As another merely illustrativeexample, cable (52) may comprise a conventional power supply cable thatplugs directly into a standard AC wall outlet, with plug (50) being anadapter that removably couples with the other end of cable (52).Similarly, regardless of whether cable (52) and plug (50) are integral,the opposite end of cable (52) may include one or more removableadapters that enable cable (52) to be selectively plugged into eithergenerator (60) or a standard AC wall outlet. For instance, the powerreceiving end of cable (52) may include an integral plug that isconfigured to plug directly into a standard AC wall outlet, and anadapter may be coupled with this plug to enable the power receiving endof cable (52) to be plugged into generator (60). Alternatively, thepower receiving end of cable (52) may include an integral plug that isconfigured to plug directly into generator, and an adapter may becoupled with this plug to enable the power receiving end of cable (52)to be plugged into a standard AC wall outlet. In versions where cable(52) is operable to plug into a standard AC wall outlet (with or withoutan adapter), cable (52) and/or plug (50) may include patient isolationcircuitry in order to comply with medical electrical equipment standards(e.g., standard ICE 60601-1).

As yet another merely illustrative variation, the end of cable (52) thatcouples directly with instrument (10) may include a plurality of plugs(50) (or adapters) to choose from, with each plug (50) (or adapter)being associated with a particular surgical modality (e.g.,electrosurgery, ultrasonic surgery, surgical stapling, etc.); and/or aparticular sub-modality (e.g., bipolar electrosurgery versus monopolarelectrosurgery, high energy ultrasonic surgery versus low energyultrasonic surgery, etc.). Some versions of instrument (10) may beconfigured to operate in more than one surgical modality and/orsub-modality. In some such versions, instrument (10) may sense themodality and/or sub-modality associated with a selected plug (50) (oradapter), and may thereby automatically configure itself to operate inthat particular modality/sub-modality. Various suitable ways in whichsuch functionality may be carried out will be apparent to those ofordinary skill in the art in view of the teachings herein. Similarly,other suitable configurations for plug (50) and cable (52), includingother suitable relationships between plug (50) and cable (52), will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Some versions of generator (60) may include a mode where generatorprovides a constant AC current as an output. Instrument (10) may beconfigured to operate based on DC power, such that an AC output ofgenerator (60) would need to be rectified. Plug (50) is operable toconvert such AC power output from generator (60) into DC power having aprofile with parameters suitable for driving surgical instrument (10).In particular, plug (50) includes a circuit (70) that providesrectification of the AC power output of generator (60) as described ingreater detail below. In versions where generator (60) is capable ofproviding additional modes of electrical output other than a simple,constant AC current, the user may manually select the mode wheregenerator (60) will provide the simple, constant AC current when theuser couples cable (52) with generator (60). Alternatively, the end ofcable (52) that plugs into generator (60) may include an EEPROM and/orother feature that is recognized by generator (60), such that generator(60) automatically selects the constant AC current output mode whencable (52) is plugged into generator (60).

As shown in FIG. 2 , circuit (70) of the present example includes a pairof inputs (72, 74) leading from cable (52) to a toroid transformer (76),which then leads to a set of four diodes (78). Diodes (78) are furthercoupled with a pair of capacitors (80, 82) in parallel, including afilter capacitor (80) and a decoupling capacitor (82). In furtherparallel with capacitors (80, 82) is a series including a currentlimiting resistor (84) and an LED (86). Circuit (70) terminates at apair of outputs (90, 92), which are coupled with control module (12)when plug (50) is fully coupled with power socket (20). Of course, theforegoing components and arrangement for circuit (70) are merelyexemplary. Various other suitable components and configurations that maybe used for circuit (70) will be apparent to those of ordinary skill inthe art in view of the teachings herein. Circuit (70) of the presentexample provides an output of approximately 12 VDC at approximately 6amps, though it should be understood that circuit (70) may insteadoutput power having any other suitable power profile.

While circuit (70) is located in plug (50) in the present example, itshould be understood that at least some components of circuit (70) (ifnot all components of circuit (70)) may be located elsewhere. By way ofexample only, at least some components of circuit (70) may be located ina module located anywhere along the length of cable (52). In addition orin the alternative, at least some components of circuit (70) may belocated in a plug (not shown) at the opposite end of cable (52), whichis received in a socket (not shown) of generator (60). In addition or inthe alternative, at least some components of circuit (70) may be locatedin surgical instrument (10).

It should be understood that generator (60) may only provide drivingpower to the circuitry in plug (50) on demand, such that instrument (10)does not actually receive driving power in the absence of user input(18) being actuated. The circuitry in plug (50) and instrument (10) maynevertheless receive enough power to recognize when user input (18) isbeing actuated. Thus, when user input (18) is in fact actuated, thecircuitry in plug (50) may send an activation signal to generator (60),which may then provide the driving power to plug (50) and instrument(10) in response to that activation signal. When the operator releasesuser input (18) or when circuitry otherwise recognizes an idle state,the circuitry in plug (50) may send an idle signal to generator (60),which may then return to an idle mode in response to that idle signal.

It should also be understood that circuit (70) may be modified such thatcable (52) may be plugged directly into a conventional AC wall outlet,such that generator (60) may simply be omitted if desired. In otherwords, cable (52) and plug (50) may be capable of providing suitablepower to instrument (10) by simply plugging cable (52) directly into aconventional AC wall outlet. Furthermore, circuit (70) may include oneor more control modules that are operable to execute control algorithms,based on the type of instrument (10) and based on data from sensor (16),etc. For instance, such control modules may execute control algorithmsthat might otherwise be executed by generator (60) when generator (60)is coupled with a conventional corded version of instrument (10). Suchcontrol algorithms may automatically tune or otherwise control the poweroutput to instrument (10), such that instrument (10) does notnecessarily just receive a constant DC power signal. In addition or inthe alternative, such control modules may be integrated into instrument(10).

In some instances, surgical instrument (10) comprises a surgicalstapling and cutting instrument. By way of example only, surgicalinstrument (10) may be constructed in accordance with at least some ofthe teachings of U.S. Pat. No. 7,416,101; U.S. Pub. No. 2009/0209990(issued as U.S. Pat. No. 8,657,174); U.S. Pub. No. 2012/0239012 (issuedas U.S. Pat. No. 8,453,914); and/or U.S. patent application Ser. No.13/716,308 (issued as U.S. Pat. No. 9,445,816). The disclosures of eachof the foregoing references are incorporated by reference herein.

As another merely illustrative example, surgical instrument (10) maycomprise an ultrasonic surgical instrument. By way of example only,surgical instrument (10) may be constructed in accordance with at leastsome of the teachings of U.S. Pat. Nos. 5,322,055; 5,873,873; 5,980,510;6,325,811; 6,783,524; U.S. Pub. No. 2006/0079874, now abandoned; U.S.Pub. No. 2007/0191713, now abandoned; U.S. Pub. No. 2007/0282333, nowabandoned; U.S. Pub. No. 2008/0200940, now abandoned; U.S. Pub. No.2010/0069940 (issued as U.S. Pat. No. 9,023,071); U.S. Pub. No.2011/0015660 (issued as U.S. Pat. No. 8,461,744); U.S. Pub. No.2012/0112687 (issued as U.S. Pat. No. 9,381,058); U.S. Pub. No.2012/0116265, now abandoned; and/or U.S. Pat. App. No. 61/410,603. Thedisclosures of each of the foregoing references are incorporated byreference herein.

As yet another merely illustrative example, surgical instrument (10) maycomprise an electrosurgical instrument. By way of example only, surgicalinstrument (10) may be constructed in accordance with at least some ofthe teachings of U.S. Pat. Nos. 6,500,176; 7,112,201; 7,125,409;7,169,146; 7,186,253; 7,189,233; 7,220,951; 7,309,849; 7,311,709;7,354,440; 7,381,209; U.S. Pub. No. 2011/0087218 (issued as U.S. Pat.No. 8,939,974); U.S. Pub. No. 2012/0116379 (issued as U.S. Pat. No.9,161,803); U.S. Pub. No. 2012/0078243 (issued as U.S. Pat. No.9,877,720); U.S. Pub. No. 2012/0078247 (issued as U.S. Pat. No.9,402,682); U.S. patent application Ser. No. 13/622,729 (issued as U.S.Pat. No. 9,089,327); U.S. patent application Ser. No. 13/622,735 (issuedas U.S. Pat. No. 9,545,253); and/or U.S. patent application Ser. No.13/658,784 (issued as U.S. Pat. No. 9,421,060). The disclosures of eachof the foregoing references are incorporated by reference herein.

In some versions, surgical instrument (10) may provide functionalitiesassociated with both ultrasonic surgical instruments and electrosurgicalinstruments. By way of example only, surgical instrument (10) may beconstructed in accordance with at least some of the teachings of U.S.Pat. No. 6,251,110, entitled “Combined Radio Frequency and UltrasonicSurgical Device,” issued Jun. 26, 2001; and/or U.S. Pub. No.2011/0015627, entitled “Impedance Monitoring Apparatus, System, andMethod for Ultrasonic Surgical Instruments,” published Jan. 20, 2011 andissued as U.S. Pat. No. 9,017,326 on Apr. 28, 2015. The disclosures ofeach of the foregoing references are incorporated by reference herein.In some such versions, the additional functionalities associated with anelectrosurgical instrument are only added when cable (52) and plug (50)are coupled with instrument (10), such that instrument (10) onlyprovides ultrasonic instrument functionalities when instrument (10) isdriven by battery (40). Similarly, coupling instrument (10) with cable(52) and plug (50) may alter the functionality of one or more userinputs (18), such that user inputs (18) provide responses that differwhen cable (52) and plug (50) are coupled with instrument (10) (ascompared to responses provided when instrument (10) is driven by battery(40)). For instance, one user input (18) that would provide anultrasonic output function when instrument (10) is driven by battery(40) may instead provide an electrosurgical output function when cable(52) and plug (50) are coupled with instrument (10).

The following describes several merely illustrative examples of how theabove teachings relating to instrument (10) may be incorporated intosurgical staplers and ultrasonic surgical instruments. Other suitableexamples will be apparent to those of ordinary skill in the art in viewof the teachings herein. Similarly, various suitable ways in which theabove teachings relating to instrument (10) may be incorporated intoelectrosurgical instruments will be apparent to those of ordinary skillin the art in view of the teachings herein.

A. Exemplary Surgical Stapler with Interchangeable Power Source Options

FIGS. 3-5 show a merely illustrative example of a form that surgicalinstrument (10) may take. In particular, FIGS. 3-5 show a surgicalstapler (100) that includes a handpiece (110), an end effector (114),and a trigger (118) that is operable to selectively actuate end effector(114). Handpiece (110) of this example includes a pistol grip (112),though it should be understood that any other suitable configuration maybe used. As shown in FIG. 3 , handpiece (110) is configured to receive abattery (140). Battery (140) is operable to power a motor (not shown) inhandpiece (110), which is further operable to drive end effector (114)in response to an operator squeezing trigger (118) toward pistol grip(112). By way of example only, surgical stapler (100) may be constructedand/or operable in accordance with at least some of the teachings ofU.S. Pat. No. 7,416,101; U.S. Pub. No. 2009/0209990 (issued as U.S. Pat.No. 8,657,174); U.S. Pub. No. 2012/0239012 (issued as U.S. Pat. No.8,453,914); and/or U.S. patent application Ser. No. 13/716,308 (issuedas U.S. Pat. No. 9,445,816), the disclosures of which are incorporatedby reference herein.

As shown in FIG. 4 , battery (140) is selectively removable fromhandpiece (110), leaving an open power socket (120) at the proximal endof handpiece (110). By way of example only, one or more resilientlybiased latch features may be used to selectively secure battery (140)within power socket (120). As shown in FIG. 5 , a plug (150) isconfigured to fit in power socket (120) in place of battery (140). Inparticular, plug (150) of this example is sized and shaped substantiallyidentically to battery (140); and includes the same kind of features asfound in battery (140) to selectively secure plug (150) to handpiece(110). Plug (150) includes an integral cable (152), which is furthercoupled with generator (60). Plug (150) may include circuitry identicalto circuitry (70) described above, such that plug (150) is ultimatelyoperable to deliver the same DC power profile to surgical instrument(100) as would otherwise be delivered by battery (140), despite thecommunication of AC power from generator (60) to plug (150) via cable(152). It should therefore be understood that plug (150), cable (152),and generator (60) together serve as a substitute for battery (140).

In an exemplary use, an operator may initially start using staplinginstrument (100) in a surgical procedure with battery (140) inserted asshown in FIG. 3 . In the event that the power level of battery (140)drops below a critical level, the operator may remove battery (140) frompower socket (120) as shown in FIG. 4 and then insert plug (150) intopower socket (120) as shown in FIG. 5 . The operator may then continueto use stapling instrument (100) in the surgical procedure. In instanceswhere the operator expects to use stapling instrument (100) repeatedlyand for an extended period of time during a particular surgicalprocedure, the operator may simply begin the procedure with plug (150)inserted in power socket (120), not using battery (140) at all. Othersuitable ways in which stapling instrument (100) may be used withbattery (140) and/or plug (150), on a selective basis, will be apparentto those of ordinary skill in the art in view of the teachings herein.

B. Exemplary Ultrasonic Surgical Instrument with Interchangeable PowerSource Options

FIGS. 6 and 8 show another merely illustrative example of a form thatsurgical instrument (10) may take. In particular, FIGS. 6 and 8 show anultrasonic surgical instrument (200) that includes a handpiece (210),which is operable to selectively couple with a modular shaft assemblyand end effector (not shown). By way of example only, such selectivecoupling and modularity may be provided in accordance with at least someof the teachings herein and/or at least some of the teachings of U.S.Pub. No. 2012/0116388, entitled “Surgical Instrument with Modular Shaftand End Effector,” published May 10, 2012 and issued as U.S. Pat. No.9,510,895 on Dec. 6, 2016, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0116394, entitled “SurgicalInstrument with Pivoting Coupling to Modular Shaft and End Effector,”published May 10, 2012 and issued as U.S. Pat. No. 9,011,471 on Apr. 21,2015, the disclosure of which is incorporated by reference herein; U.S.Pub. No. 2012/0116395, entitled “Surgical Instrument with Modular Shaftand Transducer,” published May 10, 2012 and issued as U.S. Pat. No.9,308,009 on Apr. 12, 2016, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0116260, entitled “SurgicalInstrument with Motorized Attachment Feature,” published May 10, 2012and issued as U.S. Pat. No. 10,085,792 on Oct. 2, 2018, the disclosureof which is incorporated by reference herein; U.S. Pub. No.2012/0116363, entitled “Surgical Instrument Handpiece with ResilientlyBiased Coupling to Modular Shaft and End Effector,” published May 10,2012 and issued as U.S. Pat. No. 9,375,255 on Jun. 28, 2016, thedisclosure of which is incorporated by reference herein; U.S. Pub. No.2012/0116389, entitled “Surgical Instrument Shaft with ResilientlyBiased Coupling to Handpiece,” published May 10, 2012 and issued as U.S.Pat. No. 9,421,062 on Aug. 23, 2016, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0116396, entitled“Surgical Instrument with Modular End Effector,” published May 10, 2012and issued as U.S. Pat. No. 8,998,939 on Apr. 7, 2015, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2012/0116266,entitled “Surgical Instrument with Modular End Effector and DetectionFeature,” published May 10, 2012 and now abandoned, the disclosure ofwhich is incorporated by reference herein; U.S. patent application Ser.No. 13/269,899, entitled “Ultrasonic Surgical Instrument with ModularEnd Effector,” filed Oct. 10, 2011, and issued as U.S. Pat. No.9,050,125 on Jun. 9, 2015, the disclosure of which is incorporated byreference herein; U.S. patent application Ser. No. 13/426,760, entitled“Method and Apparatus for Programming Modular Surgical Instrument,”filed Mar. 22, 2012 and issued as U.S. Pat. No. 9,364,249 on Jun. 14,2016, the disclosure of which is incorporated by reference herein;and/or U.S. patent application Ser. No. 13/484,547, entitled “LoadingCartridge for Surgical Instrument End Effector,” filed May 31, 2012 andissued as U.S. Pat. No. 9,301,772 on Apr. 5, 2016, the disclosure ofwhich is incorporated by reference herein. Other suitable ways in whichhandpiece (210) may selectively couple with a shaft assembly and endeffector will be apparent to those of ordinary skill in the art in viewof the teachings herein.

Handpiece (210) of the present example includes a pistol grip (212), atrigger (218), and buttons (219). Trigger (218) is operable tomechanically drive a clamping feature of an end effector at the distalend of a shaft assembly coupled with handpiece (210). Buttons (219) areoperable to selectively activate an ultrasonic transducer (224) withinhandpiece (210), to thereby drive an ultrasonic blade of an end effectorat the distal end of a shaft assembly coupled with handpiece (210).Pistol grip (212) defines a power socket (220) that is configured toreceive a battery (240). Pistol grip (212) further includes a pivotingdoor (226) that is operable to fully close battery (240) within powersocket (220). Battery (240) is operable to power ultrasonic transducer(224) in handpiece (210), to thereby drive an ultrasonic blade of an endeffector at the distal end of a shaft assembly coupled with handpiece(210) when buttons (219) are depressed by the operator. By way ofexample only, when a shaft assembly and end effector are coupled withhandpiece (210), ultrasonic surgical instrument (200) may be constructedand/or operable in accordance with at least some of the teachings ofU.S. Pat. Nos. 5,322,055; 5,873,873; 5,980,510; 6,325,811; 6,783,524;U.S. Pub. No. 2006/0079874, now abandoned; U.S. Pub. No. 2007/0191713,now abandoned; U.S. Pub. No. 2007/0282333, now abandoned; U.S. Pub. No.2008/0200940, now abandoned; U.S. Pub. No. 2010/0069940 (issued as U.S.Pat. No. 9,0223,071); U.S. Pub. No. 2011/0015660 (issued as U.S. Pat.No. 8,461,744); U.S. Pub. No. 2012/0112687 (issued as U.S. Pat. No.9,381,058); U.S. Pub. No. 2012/0116265, now abandoned; and/or U.S. Pat.App. No. 61/410,603, the disclosures of which are incorporated byreference herein.

In the present example, a battery guide (280) is used to guide battery(240) into power socket (220). Battery guide (280) includes a passageway(282) through which battery (240) may be passed and an outer wall (284)that may be grasped by a clinician to hold battery guide (280) inposition against the bottom of pistol grip (212). As best seen in FIG. 7, passageway (282) is defined by an inner wall (286) that is angled toassist in receiving and guiding battery (240) into alignment with powersocket (220). As also seen in FIG. 7 , battery guide (280) includes aninner recess configured to accommodate pivoting door (226) in the openposition when battery guide (280) is held against the bottom of pistolgrip (212). Other suitable configurations for battery guide (280) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

It should also be understood that battery guide (280) may be used as asterile barrier between battery (240) and the exterior of handpiece(210). In particular, in some instances handpiece (210) and batteryguide (280) are sterile while battery (240) is not sterile. One or moreclinicians with sterile hands may hold battery guide (280) against thebottom of pistol grip (212). A clinician with non-sterile hands may theninsert battery (240) through passage (282) and into power socket (220).The clinician with sterile hands may then close door (226) behindbattery (240). Thus, the hands of this clinician remain sterile, andbattery (240) has not compromised the sterility of handpiece (210)because battery guide (280) has served as a guide to position battery(240) directly into power socket (220). Battery guide (280) may bedisposed of after a single use; or may be sterilized for subsequent use.Of course, battery guide (280) is merely optional and may simply beomitted if desired. By way of example only, battery (240) may be handledin accordance with at least some of the teachings one or more of thefollowing: U.S. Pub. No. 2012/0115005, entitled “Power Source Managementfor Medical Device,” published May 10, 2012 and issued as U.S. Pat. No.9,017,849 on Apr. 28, 2015, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0110810, entitled “Medical Devicewith Feature for Sterile Acceptance of Non-Sterile Reusable Component,”published May 10, 2012 and issued as U.S. Pat. No. 9,072,523 on Jul. 7,2015, the disclosure of which is incorporated by reference herein;and/or U.S. Pub. No. 2012/0112687, entitled “Recharge System for MedicalDevices,” published May 10, 2012 and issued as U.S. Pat. No. 9,381,058on Jul. 5, 2016, the disclosure of which is incorporated by referenceherein.

As shown in FIG. 8 , a plug (250) is configured to fit through passage(282) and into power socket (220) in place of battery (240). Inparticular, plug (250) of this example is sized and shaped substantiallyidentically to battery (240). Plug (250) includes an integral cable(252), which is further coupled with generator (60). Plug (250) mayinclude circuitry identical to circuitry (70) described above, such thatplug (250) is ultimately operable to deliver the same DC power profileto surgical instrument (200) as would otherwise be delivered by battery(240), despite the communication of AC power from generator (60) to plug(250) via cable (252). It should therefore be understood that plug(250), cable (252), and generator (60) together serve as a substitutefor battery (240).

In an exemplary use, an operator may initially start using ultrasonicsurgical instrument (200) in a surgical procedure with battery (240)inserted in power socket (220). In the event that the power level ofbattery (240) drops below a critical level, the operator may removebattery (240) from power socket (220) and then insert plug (250) intopower socket (220) via guide (280) as shown in FIG. 8 . The operator maythen continue to use ultrasonic surgical instrument (200) in thesurgical procedure. In instances where the operator expects to useultrasonic surgical instrument (200) repeatedly and for an extendedperiod of time during a particular surgical procedure, the operator maysimply begin the procedure with plug (250) inserted in power socket(220), not using battery (240) at all. Other suitable ways in whichultrasonic surgical instrument (200) may be used with battery (240)and/or plug (250), on a selective basis, will be apparent to those ofordinary skill in the art in view of the teachings herein.

FIG. 9 shows another merely illustrative example of an ultrasonicsurgical instrument (300) that may serve as a variation of surgicalinstrument (10). In this example, ultrasonic surgical instrument (300)comprises a handpiece (310) that is operable to selectively couple witha modular shaft assembly and end effector (not shown), similar tohandpiece (210) described above. Handpiece (310) of the present exampleincludes a partial pistol grip (312), a trigger (318), and buttons(319). Trigger (318) and buttons (319) of this example are substantiallyidentical to trigger (218) and buttons (219) described above.

Partial pistol grip (312) is configured to couple with a plug (350),which defines the remaining portion of a full pistol grip with partialpistol grip (312). Thus, when an operator grasps handpiece (310), theoperator will grasp both partial pistol grip (312) and plug (350).Partial pistol grip (312) may alternatively couple with a battery (notshown) that defines the remaining portion of a full pistol grip withpartial pistol grip (312), such that an operator will grasp both partialpistol grip (312) and the battery when the operator grasps handpiece(310). Plug (350) includes an integral cable (352), which terminates ina generator plug (354) that couples with generator (60). Plug (350) mayinclude circuitry identical to circuitry (70) described above, such thatplug (350) is ultimately operable to deliver the same DC power profileto surgical instrument (300) as would otherwise be delivered by abattery, despite the communication of AC power from generator (60) toplug (350) via cable (352). It should therefore be understood that plug(350), cable (352), and generator (60) together serve as a substitutefor a battery.

FIG. 10 shows yet another merely illustrative example of an ultrasonicsurgical instrument (400) that may serve as a variation of surgicalinstrument (10). In this example, ultrasonic surgical instrument (400)comprises a handpiece (410) that is operable to selectively couple witha modular shaft assembly and end effector (not shown), similar tohandpiece (210) described above. Handpiece (410) of the present exampleincludes a trigger (418) and buttons (419). Trigger (418) and buttons(419) of this example are substantially identical to trigger (218) andbuttons (219) described above.

Handpiece (410) is configured to couple with a plug (450), which definesthe remaining portion of handpiece (410) including a pistol grip (451).Thus, when an operator grasps handpiece (410), the operator will graspplug (450). Handpiece (410) may alternatively couple with a battery (notshown) that defines a pistol grip, such that the operator will grasp thebattery when the operator grasps handpiece (410). Plug (450) includes anintegral cable (452), which terminates in a generator plug (454) thatcouples with generator (60). Plug (450) may include circuitry identicalto circuitry (70) described above, such that plug (450) is ultimatelyoperable to deliver the same DC power profile to surgical instrument(400) as would otherwise be delivered by a battery, despite thecommunication of AC power from generator (60) to plug (450) via cable(452). It should therefore be understood that plug (450), cable (452),and generator (60) together serve as a substitute for a battery.

Still other suitable ways in which the principals of instrument (10) maybe applied to surgical stapling instruments, ultrasonic surgicalinstruments, electrosurgical instruments, and various other kinds ofinstruments will be apparent to those of ordinary skill in the art inview of the teachings herein.

II. Exemplary Surgical Instrument with Integral Power SourceSupplemental Power Cord

In some instances, an instrument operator either cannot remove a batteryfrom an instrument during a surgical procedure or simply does not wishto remove a battery from an instrument during a surgical procedure. Forinstance, when the power level of a battery falls below an acceptablelevel, the operator may wish to quickly transition to corded power toavoid switching out the battery or waiting to recharge the battery. Thismay be due to perceived time constraints, due to sterility concerns, ordue to the battery being either non-removable or relatively difficult toremove. It may therefore be desirable in some instances to provide aninstrument that is capable of at least initially running on batterypowered; but may selectively run on corded power without having toremove the battery from the instrument. In instances where the operatorwould simply prefer to provide power from a cord rather than from abattery, regardless of the power level present in the battery, it may bedesirable to enable the operator to select corded power over batterypower at the operator's whim. FIG. 11 shows an exemplary surgicalinstrument (500) that is capable of operating on battery power or cordedpower, without requiring removal of the battery in order to operate oncorded power.

Surgical instrument (500) of this example is substantially similar tosurgical instrument (10) in many respects. For instance, surgicalinstrument (500) of this example includes a control module (512), an endeffector (514), a sensor (516), a user input (518), and an integralbattery (540). End effector (514), sensor (516), user input (518), andbattery (540) are all in communication with control module (512) viawires (522). Control module (512) is thus operable to receive inputs(e.g., power, data, etc.) from end effector (514), sensor (516), userinput (518), and/or battery (540); and to drive end effector (514) basedon one or more control algorithms and based on input received fromsensor (516) and/or user input (518). Control module (512) may comprisea microprocessor, an application specific integrated circuit (ASIC),memory, a printed circuit board (PCB), a storage device (such as a solidstate drive or hard disk), firmware, software, and/or various othersuitable components as will be apparent to those of ordinary skill inthe art in view of the teachings herein. Wires (522) may comprise anysuitable conventional wiring, traces in rigid circuit boards or flexiblecircuits, and/or any other suitable components that are operable tocommunicate electrical power and/or data/signals.

End effector (514) may include a variety of features that are operableto manipulate tissue. By way of example only, end effector (514) mayinclude one or more movable jaws that are operable to grasp tissue, atissue cutting feature (e.g., translating knife blade), a set of staplesand staple drivers operable to sever tissue, an ultrasonic bladeoperable to denature proteins in tissue by applying ultrasonic energy tothe tissue, one or more electrodes operable to provide RF energy (e.g.,bipolar or monopolar) to tissue, and/or any other suitable features aswill be apparent to those of ordinary skill in the art in view of theteachings herein. End effector (514) of this example comprises an activefeature, such as an ultrasonic blade, a pair of clamping jaws, a sharpknife, a staple driving assembly, a monopolar RF electrode, a pair ofbipolar RF electrodes, a thermal heating element, and/or various othercomponents that may be driven by electrical power. In some instances,end effector (514) is removable from the rest of surgical instrument(500) for servicing, testing, replacement, or any other purpose as willbe apparent to one of ordinary skill in the art in view of the teachingsherein. It should also be understood that surgical instrument (500) maybe configured to accept various kinds of end effectors (514) to performdifferent kinds of activities. For instance, surgical instrument (500)may accept a removable stapling end effector (514), which may be removedand replaced with an electrosurgical end effector (514), which may beremoved and replaced with an ultrasonic end effector (514), and so on.

Sensor (516) of the present example is operable to provide a variety ofinformation to control module (512) during a procedure. By way ofexample only, such configurations may include sensing a temperature atend effector (514) or determining the oscillation rate of end effector(514). Data from sensor (516) may be processed by control module (512)to effect the delivery of power to end effector (514) (e.g., in afeedback loop, etc.). Various other configurations of sensor (516) maybe provided depending upon the purpose of surgical instrument (500) aswill be apparent to those of ordinary skill in the art in view of theteachings herein. Various suitable uses for sensor (516) and variousforms that sensor (516) may take will be apparent to those of ordinaryskill in the art in view of the teachings herein. Of course, as withother components described herein, surgical instrument (500) may havemore than one sensor (516); or sensor (516) may simply be omitted ifdesired.

Trigger (518) may be configured to selectively provide power from apower source (540, 560) to end effector (514) (and/or to some othercomponent of surgical instrument (500)) to activate surgical instrument(500) when performing a procedure. By way of example only, trigger (518)may comprise one or more pushbuttons, one or more pivoting triggers, oneor more sliders, one or more knobs, and/or variations and combinationsthereof. Other suitable forms that trigger (518) may take will beapparent to those of ordinary skill in the art in view of the teachingsherein.

In the present example, battery (540) is fully integrated into surgicalinstrument (500) such that battery (540) is not removable from surgicalinstrument (500) (e.g., at least not without destroying instrument(500)). In some other examples, battery (540) is removable from surgicalinstrument (500). For instance, surgical instrument (500) may have asocket similar to power socket (20) described above. Other suitableconfigurations will be apparent to those of ordinary skill in the art inview of the teachings herein. Battery (540) may comprise a pack of oneor more NiMH batteries, Li-ion batteries (e.g., prismatic cell typelithium ion batteries, etc.), Ni-Cad batteries, or any other type ofportable power source as may be apparent to one of ordinary skill in theart in light of the teachings herein. Battery (540) may be rechargeableor not, as desired. Battery (540) is operable to provide enough power tocontrol module (512) and end effector (514) to perform at least part ofa surgical procedure.

Plug (550) of the present example is coupled with an integral cable(552), which is further removably coupled with the same kind ofgenerator (60) described above. Generator (60) is operable tocommunicate electrical power through cable (552) to plug (550), tothereby power surgical instrument (500). It should also be understoodthat cable (552) and plug (50) may be further operable to provideunidirectional or bidirectional communication of data and/or commands,etc. between surgical instrument (500) and generator (60), just like thecommunication described above with respect to instrument (10).Similarly, instrument (500) may be capable of providing wirelesscommunication with generator (60) and/or with other equipment, just likethe wireless communication described above with respect to instrument(10). Plug (550) also includes a circuit (570) that is substantiallyidentical to circuit (70) described above, such that plug (550) isoperable to rectify AC power from generator (60) to provide DC power toinstrument (500).

As shown, plug (550) is operable to couple with control module (512)and/or battery (540). In some versions, plug (550) is received in asocket that is wired directly to control module (512). Alternatively,plug (550) may be received in a socket that is wired directly to battery(540). As yet another merely illustrative example, plug (550) may bereceived in a socket that is wired directly to both control module (512)and battery (540). In some versions, when plug (550) is coupled withinstrument (500), battery (540) is bypassed through common switching,such that plug (550) provides full operational power to instrument(500). It should be understood that, in addition to providing fulloperational power to instrument (500), such that instrument (500) isfully operable from electrical power provided through plug (550), plug(550) may also be operable to charge battery (540) when plug (550) iscoupled with instrument (500). Plug (550), cable (552), and generator(60) may thus collectively serve dual roles as primary electrical powersource for instrument (500) and as recharging equipment for battery(540). In some versions, these two roles may be served simultaneously.In some other versions, plug (550), cable (552), and generator (60) onlyserve the role of recharger when plug (550), cable (552), and generator(60) are not actively being used to serve as primary electrical powersource for instrument (500). For instance, plug (550), cable (552), andgenerator (60) may serve a role as recharger for battery (540) when endeffector (514) is idle. As another merely illustrative example, plug(550), cable (552), and generator (60) may serve a role as recharger forbattery (540) in accordance with at least some of the teachings of U.S.Pub. No. 2012/0116380, entitled “Sterile Medical Instrument ChargingDevice,” published May 10, 2012 and issued as U.S. Pat. No. 9,597,143 onMar. 21, 2017, the disclosure of which is incorporated by referenceherein. Even in versions where generator (60) is operable to providerecharging capabilities via cable (552) and plug (550), cable (552) maybe configured to plug into a separate recharging device (e.g., to freeup generator (60) for some other use after surgical instrument (500) isdone being used in a surgical procedure, etc.). Of course, some versionsof battery (540) may be non-rechargeable, such that plug (550), cable(552), and generator (60) serve only as a substitute power source and/orsupplemental power source for operation of instrument (500), withoutalso providing some kind of recharging functionality. Other suitableconfigurations and operabilities will be apparent to those of ordinaryskill in the art in view of the teachings herein.

In some instances, surgical instrument (500) comprises a surgicalstapling and cutting instrument. By way of example only, surgicalinstrument (500) may be constructed in accordance with at least some ofthe teachings of U.S. Pat. No. 7,416,101; U.S. Pub. No. 2009/0209990(issued as U.S. Pat. No. 8,657,174); U.S. Pub. No. 2012/0239012 (issuedas U.S. Pat. No. 8,453,914); and/or U.S. patent application Ser. No.13/716,308 (issued as U.S. Pat. No. 9,445,816). The disclosures of eachof the foregoing references are incorporated by reference herein.

As another merely illustrative example, surgical instrument (500) maycomprise an ultrasonic surgical instrument. By way of example only,surgical instrument (500) may be constructed in accordance with at leastsome of the teachings of U.S. Pat. Nos. 5,322,055; 5,873,873; 5,980,510;6,325,811; 6,783,524; U.S. Pub. No. 2006/0079874, now abandoned; U.S.Pub. No. 2007/0191713, now abandoned; U.S. Pub. No. 2007/0282333, nowabandoned; U.S. Pub. No. 2008/0200940, now abandoned; U.S. Pub. No.2010/0069940 (issued as U.S. Pat. No. 9,023,071); U.S. Pub. No.2011/0015660 (issued as U.S. Pat. No. 8,461,744); U.S. Pub. No.2012/0112687 (issued as U.S. Pat. No. 9,381,058); U.S. Pub. No.2012/0116265, now abandoned; and/or U.S. Pat. App. No. 61/410,603. Thedisclosures of each of the foregoing references are incorporated byreference herein.

FIG. 12 shows a merely illustrative example of a form that surgicalinstrument (500) may take in an ultrasonic surgical instrument (600). Inthis example, ultrasonic surgical instrument (600) comprises a handpiece(610) that is operable to selectively couple with a modular shaftassembly and end effector (not shown), similar to handpiece (210)described above. Handpiece (610) of the present example includes apistol grip (612), a trigger (618), and buttons (619). Trigger (618) andbuttons (619) of this example are substantially identical to trigger(218) and buttons (219) described above. Pistol grip (612) houses anintegral battery (640) in this example. Pistol grip (612) includes asocket (620) that is operable to receive a plug (650). Plug (650)includes an integral cable (652), which terminates in a generator plug(654) that couples with generator (60). Plug (650) may include circuitryidentical to circuitry (70) described above, such that plug (650) isultimately operable to deliver the same DC power profile to surgicalinstrument (600) as would otherwise be delivered by battery (640),despite the communication of AC power from generator (60) to plug (650)via cable (652). It should therefore be understood that plug (650),cable (652), and generator (60) may together serve as a substitute forbattery (640). In addition or in the alternative, plug (650), cable(652), and generator (60) may together serve as a recharger for battery(640).

As yet another merely illustrative example, surgical instrument (500)may comprise an electrosurgical instrument. By way of example only,surgical instrument (500) may be constructed in accordance with at leastsome of the teachings of U.S. Pat. Nos. 6,500,176; 7,112,201; 7,125,409;7,169,146; 7,186,253; 7,189,233; 7,220,951; 7,309,849; 7,311,709;7,354,440; 7,381,209; U.S. Pub. No. 2011/0087218 (issued as U.S. Pat.No. 8,939,974); U.S. Pub. No. 2012/0116379 (issued as U.S. Pat. No.9,161,803); U.S. Pub. No. 2012/0078243 (issued as U.S. Pat. No.9,877,720); U.S. Pub. No. 2012/0078247 (issued as U.S. Pat. No.9,402,682); U.S. patent application Ser. No. 13/622,729 (issued as U.S.Pat. No. 9,089,327); U.S. patent application Ser. No. 13/622,735 (issuedas U.S. Pat. No. 9,545,253); and/or U.S. patent application Ser. No.13/658,784 (issued as U.S. Pat. No. 9,421,060). The disclosures of eachof the foregoing references are incorporated by reference herein.

In some versions, surgical instrument (500) may provide functionalitiesassociated with both ultrasonic surgical instruments and electrosurgicalinstruments. By way of example only, surgical instrument (500) may beconstructed in accordance with at least some of the teachings of U.S.Pat. No. 6,251,110, entitled “Combined Radio Frequency and UltrasonicSurgical Device,” issued Jun. 26, 2001; and/or U.S. Pub. No.2011/0015627, entitled “Impedance Monitoring Apparatus, System, andMethod for Ultrasonic Surgical Instruments,” published Jan. 20, 2011 andissued as U.S. Pat. No. 9,017,326 on Apr. 28, 2015. The disclosures ofeach of the foregoing references are incorporated by reference herein.In some such versions, the additional functionalities associated with anelectrosurgical instrument are only added when cable (552) and plug(550) are coupled with instrument (500), such that instrument (500) onlyprovides ultrasonic instrument functionalities when instrument (500) isdriven solely by battery (540). Similarly, coupling instrument (500)with cable (552) and plug (550) may alter the functionality of one ormore user inputs (518), such that user inputs (518) provide responsesthat differ when cable (552) and plug (550) are coupled with instrument(500) (as compared to responses provided when instrument (500) is drivensolely by battery (540)). For instance, one user input (518) that wouldprovide an ultrasonic output function when instrument (500) is drivensolely by battery (540) may instead provide an electrosurgical outputfunction when cable (552) and plug (550) are coupled with instrument(500).

Still other suitable ways in which the principals of instrument (500)may be applied to surgical stapling instruments, ultrasonic surgicalinstruments, electrosurgical instruments, and various other kinds ofinstruments will be apparent to those of ordinary skill in the art inview of the teachings herein.

III. Exemplary Alternative Plug Assembly

FIG. 13 depicts an exemplary alternative plug assembly (700) that may beused in place of plugs (50, 500) described above. Other than asdescribed below, it should be understood that plug assembly (700) may beconfigured and/or operable in accordance with the teachings aboveregarding plugs (50, 500). Plug assembly (700) of this example comprisesa first plug housing (702) joined with a second plug housing (704). Insome other versions, a single plug housing is used instead. Plug housing(704) of the present example is configured similar to the housing ofbattery (40), such that plug housing (704) is removably received insocket (20) just like battery (40). Plug housing (702) is alsoconfigured similar to the housing of battery (40), though this is ofcourse optional. A restraint feature (706) removably secures plugassembly (700) relative to instrument (10). By way of example only,restraint feature (706) may comprise a resilient latch, a clip, a clamp,and/or any other suitable structure. A contact and support feature (708)provides structural support for plug assembly (700) relative toinstrument (10); and electrical continuity with instrument (10). Varioussuitable forms that contact and support feature (708) may take will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Plug housing (704) also contains a printed circuit board (710), which isin electrical communication with contact and support feature (708). Plughousing (702) contains a transformer (712), which is in electricalcommunication with printed circuit board (710). Transformer (712) may beconfigured similar to transformer (76) described above. In someversions, printed circuit board (710) includes components similar to theremaining components of circuit (70) described above. It shouldtherefore be understood that plug assembly (700) may include the samecomponents as circuit (70) described above and/or other components aswill be apparent to those of ordinary skill in the art in view of theteachings herein. It should also be understood that such components maybe allocated among either housing (702, 704) as desired.

A cable (714) extends from housing (702) and is in electricalcommunication with transformer (76). A plug (718) is located at theopposite end of cable (714), and is configured to plug into acorresponding socket of generator (60). An LED indicator (716) is alsopositioned on housing (702) in this example. LED indicator (716) isoperable to selectively illuminate to indicate an operational state ofplug assembly (700). By way of example only, LED indicator (716) mayilluminate to indicate successful coupling between generator (60) andinstrument (10). In addition or in the alternative, LED indicator (716)may flash to indicate delivery of power to tissue via end effector (14).LED indicator (716) may provide numerous flashing patterns to indicatenumerous operational conditions, fault conditions, etc. Similarly, LEDindicator (716) may illuminate in different colors to indicate differentconditions. Various suitable forms of user feedback that may be providedthrough LED indicator (716) will be apparent to those of ordinary skillin the art in view of the teachings herein. Similarly, other suitablekinds of features that may be used in addition to or in lieu of LEDindicator (716) to provide audio and/or visual feedback to a user willbe apparent to those of ordinary skill in the art in view of theteachings herein.

IV. Exemplary Surgical Instrument with Modular Shaft Assembly

Any of the versions of surgical instrument (10) described herein (orother versions of surgical instrument (10)) may be configured to have amodular end effector or shaft assembly. For instance, surgicalinstrument (10) may have a handpiece or other kind of body thatremovably receives various kinds of shaft assemblies. Such various kindsof shaft assemblies may include those having tissue stapling features,ultrasonic blades, RF energy electrodes, surgical clip applyingfeatures, etc., such that the selection of shaft assemblies presentsoptions for a surgeon to operate with various surgical modalities usingthe same handpiece. The handpiece may include features that are operableto drive the various kinds of end effectors of shaft assemblies. In someinstances, shaft assemblies may be interchanged among the same handpieceduring the same surgical procedure. It should also be understood that,if desired, a handpiece may be provided as a reusable component whilethe shaft assembly is provided as a disposable component.

Various examples of surgical instruments that have modular end effectorsor shaft assemblies are described in U.S. Pub. No. 2012/0116388 (issuedas U.S. Pat. No. 9,510,895), the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0116394 (issued as U.S. Pat. No.9,011,471), the disclosure of which is incorporated by reference herein;U.S. Pub. No. 2012/0116395 (issued as U.S. Pat. No. 9,308,009), thedisclosure of which is incorporated by reference herein; U.S. Pub. No.2012/0116260 (issued as U.S. Pat. No. 10,085,792), the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2012/0116363(issued as U.S. Pat. No. 9,375,255), the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0116389 (issued asU.S. Pat. No. 9,421,062), the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0116396 (issued as U.S. Pat. No.8,998,939), the disclosure of which is incorporated by reference herein;U.S. Pub. No. 2012/0116266, the disclosure of which is incorporated byreference herein; U.S. patent application Ser. No. 13/269,899 (issued asU.S. Pat. No. 9,050,125), the disclosure of which is incorporated byreference herein; U.S. patent application Ser. No. 13/426,760 (issued asU.S. Pat. No. 9,364,249), the disclosure of which is incorporated byreference herein; and/or U.S. patent application Ser. No. 13/484,547(issued as U.S. Pat. No. 9,301,772), the disclosure of which isincorporated by reference herein. Further examples of how surgicalinstrument (10) may incorporate a modular end shaft assembly will bedescribed in greater detail below; while additional examples will beapparent to those of ordinary skill in the art in view of the teachingsherein. It should be understood that the teachings below may be readilycombined with any other teachings herein and/or various teachings in thenumerous references that are cited herein.

FIG. 14 shows an exemplary handpiece (1000) that is configured to couplewith various exemplary shaft assemblies, including but not limited toshaft assemblies (1100, 1200, 1300) described below. Handpiece (1000)includes a housing (1002) that defines a pistol grip (1004) and a shaftsocket (1006). While a pistol grip (1004) is provided by handpiece(1000) in this example, it should be understood that any other suitablekind of grip may be provided. Shaft socket (1006) is configured toreceive a complementary control interface feature of a shaft assembly.Handpiece (1000) also includes various drive features that are operableto drive a shaft assembly via shaft socket (1006), such as electricaldrive features (e.g., wires, battery, etc.), ultrasonic drive features(e.g., ultrasonic transducer, etc.), mechanical drive features (e.g.,gears, motors, etc.), etc. However, in the present example, handpiece(1000) does not include user input features that are operable toactivate drive features in handpiece (1000). Instead, those drivefeatures are provided by the shaft assemblies that are coupled withhandpiece (1000). This may avoid the prospect of having unused controlfeatures on handpiece (1000) and may promote acceptance of shaftassemblies that have user input features that are not yet contemplated.

FIG. 15 shows one merely exemplary shaft assembly (1100) that may beremovably coupled with handpiece (1000). Shaft assembly (1100) comprisesa control interface feature (1102) that is configured for receipt insocket (1006) of handpiece (1000). Shaft assembly (1100) also includes adistally extending shaft (1104) and an optional knob (1105) that isoperable to rotate shaft (1104). An end effector (not shown) at thedistal end of shaft (1104) may include numerous components, includingbut not limited to a stapling assembly, an ultrasonic blade, RFelectrodes, etc. Components of the end effector may be driven by thedrive features within handpiece (1000), with theelectrical/acoustic/mechanical/etc. actuation being communicated throughsocket (1006), control interface feature (1102), and shaft (1104).

Shaft assembly (1100) of this example also includes a first activationbutton (1106) and a second activation button (1008). Activation buttons(1106, 1108) are positioned for engagement by fingers of the same handthat grasps pistol grip (1004). Activation buttons (1106, 1108) areoperable to selectively activate drive features in handpiece (1000). Byway of example only, activation button (1106) may activate handpiece(1000) to drive an ultrasonic blade at the distal end of shaft (1104) ata high power level; while activation button (1108) may activatehandpiece to drive the same ultrasonic blade at a low power level. Othersuitable responses that may be triggered by activation buttons (1106,1108) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

FIG. 16 shows another exemplary shaft assembly (1200) that may beremovably coupled with handpiece (1000). Shaft assembly (1200) comprisesa control interface feature (1202) that is configured for receipt insocket (1006) of handpiece (1000). Shaft assembly (1200) also includes adistally extending shaft (1204) and an optional knob (1205) that isoperable to rotate shaft (1204). An end effector (not shown) at thedistal end of shaft (1204) may include numerous components, includingbut not limited to a stapling assembly, an ultrasonic blade, RFelectrodes, etc. Components of the end effector may be driven by thedrive features within handpiece (1000), with theelectrical/acoustic/mechanical/etc. actuation being communicated throughsocket (1006), control interface feature (1202), and shaft (1204).

Shaft assembly (1200) of this example also includes a control dial(1206) that is rotatable about an axis (A₁). Control dial (1206) ispositioned for engagement by fingers of the same hand that grasps pistolgrip (1004). Control dial (1206) is operable to selectively activatedrive features in handpiece (1000). By way of example only, shaft (1204)may include an articulation section that is operable to selectivelydeflect the end effector laterally away from the longitudinal axis ofshaft (1204). Handpiece (1000) may include a drive feature that isoperable to drive such articulation in response to rotation of controldial (1206). Other suitable responses that may be triggered by controldial (1206) will be apparent to those of ordinary skill in the art inview of the teachings herein.

FIG. 17 shows another exemplary shaft assembly (1300) that may beremovably coupled with handpiece (1000). Shaft assembly (1300) comprisesa control interface feature (1302) that is configured for receipt insocket (1006) of handpiece (1000). Shaft assembly (1300) also includes adistally extending shaft (1304) and an optional knob (1305) that isoperable to rotate shaft (1304). An end effector (not shown) at thedistal end of shaft (1304) may include numerous components, includingbut not limited to a stapling assembly, an ultrasonic blade, RFelectrodes, etc. Components of the end effector may be driven by thedrive features within handpiece (1000), with theelectrical/acoustic/mechanical/etc. actuation being communicated throughsocket (1006), control interface feature (1302), and shaft (1304).

Shaft assembly (1300) of this example also includes a pivoting trigger(1306) and an activation button (1308). Trigger (1306) and button (1308)are operable to selectively activate drive features in handpiece (1000).By way of example only, the end effector at the distal end of shaft(1304) may include clamping jaws and RF electrodes that are operable toapply bipolar RF energy to tissue clamped between the jaws. In some suchversions, trigger (1306) may activate handpiece (1000) to drive the jawsto a closed position; while button (1308) may activate handpiece (1000)to provide RF energy to the electrodes of the jaws. Other suitableresponses that may be triggered by trigger (1306) and activation button(1308) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

FIG. 18 shows another exemplary handpiece (1400) that is configured tocouple with various exemplary shaft assemblies, including but notlimited to shaft assemblies (1500, 1600) described below. Handpiece(1400) includes a housing (1402) that defines a pistol grip (1404) and ashaft socket (1406). While a pistol grip (1404) is provided by handpiece(1400) in this example, it should be understood that any other suitablekind of grip may be provided. Shaft socket (1406) is configured toreceive a complementary control interface feature of a shaft assembly.Handpiece (1400) also includes various drive features that are operableto drive a shaft assembly via shaft socket (1406), such as electricaldrive features (e.g., wires, battery, etc.), ultrasonic drive features(e.g., ultrasonic transducer, etc.), mechanical drive features (e.g.,gears, motors, etc.), etc. In addition, handpiece (1400) includes afirst activation button (1408) and a second activation button (1410),each of which are operable to selectively activate corresponding drivefeatures in handpiece (1400). Handpiece (1400) of this example alsoincludes a control zone (1420) associated with control inputs ofattached shaft assemblies. Providing such a consistent location forcontrol inputs of an attached shaft assembly may make operation of theinstrument more intuitive and familiar for an operator. Of course, thedesignation of a control zone (1420) is merely optional.

FIG. 19 shows one merely exemplary shaft assembly (1500) that may beremovably coupled with handpiece (1400). Shaft assembly (1500) comprisesa control interface feature (1502) that is configured for receipt insocket (1406) of handpiece (1000). Shaft assembly (1500) also includes adistally extending shaft (1504) and an optional knob (1505) that isoperable to rotate shaft (1504). An end effector (not shown) at thedistal end of shaft (1504) may include numerous components, includingbut not limited to a stapling assembly, an ultrasonic blade, RFelectrodes, etc. Components of the end effector may be driven by thedrive features within handpiece (1400), with theelectrical/acoustic/mechanical/etc. actuation being communicated throughsocket (1406), control interface feature (1502), and shaft (1504).

In the present example, shaft (1504) also includes an articulationsection that is operable to selectively deflect the end effectorlaterally away from the longitudinal axis of shaft (1504). Thisarticulation is controlled by a ring (1506) of shaft assembly (1500).Ring (1506) includes a first laterally extending paddle (1508) and asecond laterally extending paddle (1510). Ring (1506) is rotatable aboutthe longitudinal axis of shaft (1504) to activate articulation. Inparticular, when ring (1506) is rotated in a first angular directionabout the longitudinal axis of shaft (1504) (e.g. clockwise), a drivefeature in handpiece (1400) drives the end effector to deflect in afirst lateral direction away from the longitudinal axis of shaft (1504)(e.g., to the right). When ring (1506) is rotated in the oppositeangular direction about the longitudinal axis of shaft (1504)(e.g.,counterclockwise), a drive feature in handpiece (1400) drives the endeffector to deflect in a second lateral direction away from thelongitudinal axis of shaft (1504)(e.g., to the left). Paddles (1508,1510) are positioned at control zone (1420), such that the operator mayuse paddles (1508, 1510) to rotate ring (1506) using the same hand thatgrasps pistol grip (1404). Other suitable responses that may betriggered by ring (1506) will be apparent to those of ordinary skill inthe art in view of the teachings herein.

FIG. 20 shows another merely exemplary shaft assembly (1600) that may beremovably coupled with handpiece (1400). Shaft assembly (1600) comprisesa control interface feature (1602) that is configured for receipt insocket (1406) of handpiece (1000). Shaft assembly (1600) also includes adistally extending shaft (1604) and an optional knob (1605) that isoperable to rotate shaft (1604). An end effector (not shown) at thedistal end of shaft (1604) may include numerous components, includingbut not limited to a stapling assembly, an ultrasonic blade, RFelectrodes, etc. Components of the end effector may be driven by thedrive features within handpiece (1400), with theelectrical/acoustic/mechanical/etc. actuation being communicated throughsocket (1406), control interface feature (1602), and shaft (1604).

In the present example, shaft (1604) also includes an articulationsection that is operable to selectively deflect the end effectorlaterally away from the longitudinal axis of shaft (1604). Thisarticulation is controlled by buttons (1608, 1610) of shaft assembly(1610). Buttons (1608, 1610) are positioned at the free ends of opposingarms (1609), which are secured to a ring (1606). In the present example,ring (1606) is not rotatable, though it should be understood that ring(1606) may be rotatable in other versions to provide another form ofuser input to drive the end effector, etc. Buttons (1608, 1610) areconfigured to be pressed inwardly and are positioned at control zone(1420), such that the operator may press buttons (1608, 1610) using thesame hand that grasps pistol grip (1404). When button (1608) is pressed,a drive feature in handpiece a drive feature in handpiece (1400) drivesthe end effector to deflect in a first lateral direction away from thelongitudinal axis of shaft (1504)(e.g., to the left). When button (1610)is pressed, a drive feature in handpiece a drive feature in handpiece(1400) drives the end effector to deflect in a second lateral directionaway from the longitudinal axis of shaft (1504)(e.g., to the right). Insome other versions, both buttons (1608, 1610) at the end of one arm(1609) are operable to cause end effector articulation in the firstlateral direction; while buttons (1608, 1610) at the end of the otherarm (1609) are operable to cause end effector articulation in the secondlateral direction. Other suitable responses that may be triggered bybuttons (1608, 1610) will be apparent to those of ordinary skill in theart in view of the teachings herein.

FIG. 21 shows yet another exemplary handpiece (1700) that is configuredto couple with various exemplary shaft assemblies, including but notlimited to shaft assemblies (1800, 1900, 2000) described below.Handpiece (1700) includes a housing (1702) that defines a pistol grip(1704) and a shaft socket (1706). While a pistol grip (1704) is providedby handpiece (1700) in this example, it should be understood that anyother suitable kind of grip may be provided. Shaft socket (1706) isconfigured to receive a complementary control interface feature of ashaft assembly. Handpiece (1700) also includes various drive featuresthat are operable to drive a shaft assembly via shaft socket (1706),such as electrical drive features (e.g., wires, battery, etc.),ultrasonic drive features (e.g., ultrasonic transducer, etc.),mechanical drive features (e.g., gears, motors, etc.), etc. In addition,handpiece (1700) includes a first activation button (1708) and a secondactivation button (1710), each of which are operable to selectivelyactivate corresponding drive features in handpiece (1700). Handpiece(1400) of this example also includes a control zone (1720) associatedwith control inputs of attached shaft assemblies. Providing such aconsistent location for control inputs of an attached shaft assembly maymake operation of the instrument more intuitive and familiar for anoperator. Of course, the designation of a control zone (1720) is merelyoptional.

FIG. 22 shows one merely exemplary shaft assembly (1800) coupled withhandpiece (1700). Shaft assembly (1800) comprises a control interfacefeature (not shown) that is disposed in socket (1706) of handpiece(1700). Shaft assembly (1800) also includes a distally extending shaft(1804) and an optional knob (1805) that is operable to rotate shaft(1804). An end effector (not shown) at the distal end of shaft (1804)may include numerous components, including but not limited to a staplingassembly, an ultrasonic blade, RF electrodes, etc. Components of the endeffector may be driven by the drive features within handpiece (1700),with the electrical/acoustic/mechanical/etc. actuation beingcommunicated through socket (1706), the control interface feature ofshaft assembly (1800), and shaft (1804).

Shaft assembly (1800) of this example also includes a pivoting trigger(1806). Trigger (1806) is operable to selectively activate a drivefeature in handpiece (1700). By way of example only, the end effector atthe distal end of shaft (1804) may include clamping jaws and RFelectrodes that are operable to apply bipolar RF energy to tissueclamped between the jaws. In some such versions, trigger (1806) mayactivate handpiece (1700) to drive the jaws to a closed position; whileone or both of buttons (1708, 1710) may activate handpiece (1700) toprovide RF energy to the electrodes of the jaws. Trigger (1806) ispositioned at control zone (1720), such that the operator may pivottrigger (1806) using the same hand that grasps pistol grip (1704). Othersuitable responses that may be triggered by trigger (1806) will beapparent to those of ordinary skill in the art in view of the teachingsherein.

FIG. 23 shows another merely exemplary shaft assembly (1900) coupledwith handpiece (1700). Shaft assembly (1900) comprises a controlinterface feature (not shown) that is disposed in socket (1706) ofhandpiece (1700). Shaft assembly (1900) also includes a distallyextending shaft (1904) and an optional knob (1905) that is operable torotate shaft (1904). An end effector (not shown) at the distal end ofshaft (1904) may include numerous components, including but not limitedto a stapling assembly, an ultrasonic blade, RF electrodes, etc.Components of the end effector may be driven by the drive featureswithin handpiece (1700), with the electrical/acoustic/mechanical/etc.actuation being communicated through socket (1706), the controlinterface feature of shaft assembly (1900), and shaft (1904).

Shaft assembly (1900) of this example also includes a pivoting paddle(1906), which is pivotable about an axis (A₂). Paddle (1906) is operableto selectively activate drive features in handpiece (1700). By way ofexample only, shaft (1904) may include an articulation section that isoperable to selectively deflect the end effector laterally away from thelongitudinal axis of shaft (1904). Handpiece (1700) may include a drivefeature that is operable to drive such articulation in response topivoting of paddle (1906). Paddle (1906) is positioned at control zone(1720), such that the operator may pivot paddle (1906) using the samehand that grasps pistol grip (1704). Other suitable responses that maybe triggered by paddle (1906) will be apparent to those of ordinaryskill in the art in view of the teachings herein.

FIG. 24 shows another merely exemplary shaft assembly (2000) coupledwith handpiece (1700). Shaft assembly (2000) comprises a controlinterface feature (not shown) that is disposed in socket (1706) ofhandpiece (1700). Shaft assembly (2000) also includes a distallyextending shaft (2004) and an optional knob (2005) that is operable torotate shaft (2004). An end effector (not shown) at the distal end ofshaft (2004) may include numerous components, including but not limitedto a stapling assembly, an ultrasonic blade, RF electrodes, etc.Components of the end effector may be driven by the drive featureswithin handpiece (1700), with the electrical/acoustic/mechanical/etc.actuation being communicated through socket (1706), the controlinterface feature of shaft assembly (2000), and shaft (2004). Shaftassembly (2000) of this example also includes an activation button(2006) located at a proximal end of an arm (2008). Button (2006) isoperable to activate a drive feature in handpiece to selectively drivean element in the end effector at the distal end of shaft (2004).Various suitable responses that may be triggered by button (2006) willbe apparent to those of ordinary skill in the art in view of theteachings herein. It should also be understood that button (2006) ispositioned just proximal to control zone (1720) in this example, suchthat the operator may press button (2006) using the same hand thatgrasps pistol grip (1704).

V. Miscellaneous

In any of the examples described herein, it should be understood that afootswitch may be used to selectively activate one or more features ofthe surgical instrument. By way of example only, such a footswitch maybe directly coupled with generator (60). A footswitch may enable theoperator to selectively activate one or more features of the surgicalinstrument simply by actuating the footswitch. In addition or in thealternative, the operator may need to actuate one or more user inputfeatures on the surgical instrument and actuate a footswitchsimultaneously in order to selectively activate one or more features ofthe surgical instrument. Various other suitable ways in which afootswitch may be incorporated with the teachings herein will beapparent to those of ordinary skill in the art.

It should be understood that any of the versions of surgical instrumentsdescribed herein may include various other features in addition to or inlieu of those described above. By way of example only, any of thedevices herein may also include one or more of the various featuresdisclosed in any of the various references that are incorporated byreference herein. It should also be understood that the teachings hereinmay be readily applied to any of the instruments described in any of thereferences cited herein, such that the teachings herein may be readilycombined with the teachings of any of the references cited herein innumerous ways. Other types of instruments into which the teachingsherein may be incorporated will be apparent to those of ordinary skillin the art.

Similarly, it should be understood that any one or more of theteachings, expressions, embodiments, examples, etc. described herein maybe combined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should also be understood that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool withUltrasound Cauterizing and Cutting Instrument,” published Aug. 31, 2004,the disclosure of which is incorporated by reference herein.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a userimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. A kit for a surgical instrument, comprising: an endeffector including an active feature configured to operate on a tissue;a shaft assembly defining a longitudinal axis and extending from aproximal end portion to a distal end portion, wherein the end effectoris configured to distally extend from the distal end portion; a bodyremovably coupled with the shaft assembly in a connected state andseparated from the shaft assembly in a disconnected state, wherein thebody defines a shaft socket configured to receive the proximal endportion of the shaft assembly, wherein the body comprises a drivefeature configured to drive operation of the active feature of the endeffector, wherein the drive feature includes at least one of anultrasonic drive feature or a mechanical drive feature; a pivotingtrigger positioned on the shaft assembly, wherein the pivoting triggeris configured to selectively activate the drive feature of the body toactuate the end effector in the connected state, and wherein thepivoting trigger is configured to be separated from the body in thedisconnected state; and at least one activation feature positioned onthe body configured to selectively activate the drive feature of thebody in the connected state, wherein the shaft socket and the proximalend portion of the shaft assembly are configured to communicateactivation of the drive feature therethrough to selectively driveoperation of the active feature of the end effector in the connectedstate, and wherein the proximal end portion of the shaft assembly isconfigured to be removed from the socket to separate the pivotingtrigger in the disconnected state.
 2. The kit of claim 1, wherein thebody defines a pistol grip configured to be grasped by a hand, whereinthe at least one activation feature is positioned relative to the pistolgrip such that the at least one activation feature is positioned forengagement by the hand that grasps the pistol grip.
 3. The kit of claim1, wherein the pivoting trigger is pivotable about an axis transverse tothe longitudinal axis of the shaft assembly.
 4. The kit of claim 1,wherein the shaft assembly includes an articulation section configuredto deflect the end effector away from the longitudinal axis, wherein theat least one activation feature includes a ring configured to activatethe articulation section of the shaft.
 5. The kit of claim 4, whereinthe ring is rotatable about the longitudinal axis to activatearticulation of the articulation section, wherein the ring is configuredto rotate in a first annular direction to activate the drive feature inthe body to deflect the end effector in a first lateral direction awayfrom the longitudinal axis, wherein the ring is configured to rotate ina second annular direction to activate the drive feature in the body todeflect the end effector in a second lateral direction away from thelongitudinal axis.
 6. The kit of claim 1, wherein the shaft assemblyincludes a knob configured to rotate the shaft of the shaft assembly. 7.The kit of claim 1, wherein the active feature of the end effector isselected from the group consisting of: an ultrasonic blade, at least oneelectrode operable to apply RF energy to the tissue, and a stapler. 8.The kit of claim 1, wherein the drive feature includes an ultrasonicdrive feature.
 9. The kit of claim 1, wherein the pivoting trigger ispositioned between the at least one activation feature of the body andthe longitudinal axis.
 10. A kit for a surgical instrument comprising:an end effector including an ultrasonic blade configured to operate on atissue; a shaft assembly having a proximal end portion and a distal endportion, wherein the end effector is configured to extend from thedistal end portion of the shaft assembly, wherein the proximal endportion of the shaft assembly includes a first lateral side and a secondlateral side disposed opposite to the first lateral side; a bodyremovably coupled with the shaft assembly, wherein the body defines ashaft socket configured to receive the proximal end portion of the shaftassembly, wherein the body comprises an ultrasonic transducer configuredto drive operation of the ultrasonic blade of the end effector, whereinthe body defines a pistol grip configured to be grasped by a hand duringoperation of the end effector; a first articulation feature disposed onthe first lateral side and configured to activate the drive feature todeflect the end effector away from the longitudinal axis in a firstdirection; a second articulation feature disposed on the second lateralside and configured to activate the drive feature to deflect the endeffector away from the longitudinal axis in a second direction oppositeto the first direction; and at least one activation feature positionedon the shaft assembly and configured to selectively activate theultrasonic transducer of the body, wherein the shaft socket and theproximal end portion of the shaft assembly are configured to communicateactivation of the ultrasonic transducer therethrough to drive operationof the ultrasonic blade of the end effector, wherein the at least oneactivation feature is positioned relative to the pistol grip such thatthe at least one activation feature is positioned for engagement by thehand that grasps the pistol grip.
 11. The kit of claim 10, wherein theproximal end portion includes opposing first and second proximallyextending arms, wherein the first articulation feature is positioned ata proximal end of the first proximally extending arm, wherein the secondarticulation feature is positioned at a proximal end of the secondproximally extending arm.
 12. The kit of claim 10, wherein the first andsecond articulation features are laterally extending paddles or buttons.